Hybrid internal combustion engine and air motor system and method

ABSTRACT

A hybrid internal combustion engine and air motor system is provided and includes at least one chamber having a drivable member and at least one intake valve and at least one exhaust valve, and a reservoir connected to the chamber through at least one of the intake valve and the exhaust valve. The system further comprises a computer configured to calculate air compressor efficiency during an air compressor mode of operation and select an intake and exhaust valve opening and closing timing sequence for maximizing air compressor efficiency and/or a computer configured to calculate air motor efficiency during an air motor mode of operation and select an intake and exhaust valve opening and closing timing sequence for maximizing air motor efficiency. A method for selecting an intake and exhaust valve opening and closing timing sequence for maximizing air compressor efficiency and/or for selecting an intake and exhaust valve opening and closing timing sequence for maximizing air motor efficiency is also disclosed.

The present application is a divisional of U.S. application Ser. No.13/434,941, filed Mar. 30, 2012, which is a divisional of U.S.application Ser. No. 12/522,587, filed Jul. 9, 2009, now U.S. Pat. No.8,177,016, issued May 15, 2012, which is a U.S. national stageapplication of PCT/US2007/060671, filed Jan. 18, 2007, both of which areincorporated by reference.

BACKGROUND AND SUMMARY

The present invention relates generally to hybrid internal combustionengine and air motor systems and methods and, more particularly, to suchsystems and methods wherein intake and exhaust valve opening and closingtiming sequences during air motor or air compressor modes of operationare selected to maximize air motor efficiency or air compressorefficiency.

Typical city driving patterns for vehicles include many accelerationsand decelerations. A significant portion of fuel energy is spent inaccelerating the vehicle. This energy is wasted during subsequentdecelerations. A pneumatic hybrid engine captures and reuses some ofthis energy. During braking, the engine can utilize the braking energyto work as a compressor, pumping compressed air into an on-board tank.Later, during acceleration, the engine can be powered by the storedcompressed air with or without burning diesel fuel to get up to speed oruntil the compressed air is depleted. The additional work performed bythe compressed air permits a reduction in the quantity of fuel needed toachieve the required engine power. In this way, the engine efficiencycan be increased, and the vehicle fuel economy can be improved.

It is desirable to provide a method for controlling air flow in aircompressor modes and air motor modes of such pneumatic-hybrid vehicles.It is also desirable to provide a system arranged to control air flow inair compressor modes and air motor modes of such air-hybrid systems.

It is also desirable to provide a method for transitioning from airmotor mode to internal combustion engine mode in a manner that minimizeschanges in engine torque. It is also desirable to provide a systemarranged to transition from air motor mode to internal combustion enginemode in a manner that minimizes changes in engine torque.

According to an aspect of the present invention, a method is providedfor operating a hybrid internal combustion engine and air motor systemcomprising at least one chamber having a drivable member and at leastone intake valve and at least one exhaust valve, and a reservoirconnected to the chamber through at least one of the intake valve andthe exhaust valve. The method comprises, in an air compressor mode ofoperation, calculating air compressor efficiency according to thefollowing equation:

${\eta \; {AC}} = {{{efficiency}\mspace{14mu} {of}\mspace{14mu} {air}\mspace{14mu} {compressor}} = {- \frac{A}{W}}}$

and wherein

$\begin{matrix}{A = {{thermodynamic}\mspace{14mu} {availability}\mspace{14mu} {in}\mspace{14mu} {resevoir}}} \\{= {\left( {E - E_{o}} \right) + {P_{o}*\left( {V - V_{o}} \right)} - {T_{o}*\left( {S - S_{o}} \right)}}}\end{matrix}$

dA=rate of change of A

E=Internal energy of air in reservoir=f(m, T_(t))

m=mass of air in reservoir=P_(t)*V/(R*T_(t))

T_(t)=Temperature of air in reservoir

P_(t)=Pressure of air in reservoir

V=Volume of reservoir at P_(t) and T_(t)

R=gas constant

E_(o)=Internal energy of air in reservoir at ambient pressure andtemperature

P_(o)=Ambient pressure

V_(o)=Volume of air in reservoir at ambient pressure and temperature

T_(o)=Temperature of ambient air

S=Entropy of air in reservoir=f (P, T_(t))

S_(o)=Entropy of air in reservoir at ambient pressure and temperature

POW=Engine brake power=N*T_(b)

N=Engine speed (rev/time)

T_(b)=Engine brake torque

W=Engine brake work=POW dt

dW=rate of change of W

An intake and exhaust valve opening and closing timing sequence isselected for maximizing air compressor efficiency so that

$\frac{\left( {\eta \; {AC}} \right)}{\left( {{Valve}\mspace{14mu} {Timing}} \right)} = 0$and$\frac{^{2}\left( {\eta \; {AC}} \right)}{^{2}\left( {{Valve}\mspace{14mu} {Timing}} \right)} < 0.$

According to another aspect of the present invention, a method foroperating a hybrid internal combustion engine and air motor systemcomprising at least one chamber having a drivable member and at leastone intake valve and at least one exhaust valve, and a reservoirconnected to the chamber through the exhaust valve is provided. Themethod comprises, in an air motor mode of operation, calculating airmotor efficiency according to the following equation:

${\eta {AM}} = {{{efficiency}\mspace{14mu} {of}\mspace{14mu} {air}\mspace{14mu} {motor}}\mspace{14mu} = {- \frac{W}{A}}}$

and wherein

$\begin{matrix}{A = {{thermodynamic}\mspace{14mu} {availability}\mspace{14mu} {in}\mspace{14mu} {resevoir}}} \\{= {\left( {E - E_{o}} \right) + {P_{o}*\left( {V - V_{o}} \right)} - {T_{o}*\left( {S - S_{o}} \right)}}}\end{matrix}$

dA=rate of change of A

E=Internal energy of air in reservoir=f(m, T_(t))

m=mass of air in reservoir=P_(t)*V/(R*T_(t))

T_(t)=Temperature of air in reservoir

P_(t)=Pressure of air in reservoir

V=Volume of reservoir at P_(t) and T_(t)

R=gas constant

E_(o)=Internal energy of air in reservoir at ambient pressure andtemperature

P_(o)=Ambient pressure

V_(o)=Volume of air in reservoir at ambient pressure and temperature

T_(o)=Temperature of ambient air

S=Entropy of air in reservoir=f (P_(t), T_(t))

S_(o)=Entropy of air in reservoir at ambient pressure and temperature

POW=Engine brake power=N*T_(b)

N=Engine speed (rev/time)

T_(b)=Engine brake torque

W=Engine brake work=POW dt

dW=rate of change of W

An intake and exhaust valve opening and closing timing sequence isselected for maximizing air motor efficiency so that

$\frac{\left( {\eta \; {AM}} \right)}{\left( {{Valve}\mspace{14mu} {Timing}} \right)} = 0$and$\frac{^{2}\left( {\eta \; {AM}} \right)}{^{2}\left( {{Valve}\mspace{14mu} {Timing}} \right)} < 0.$

According to another aspect of the present invention, a method isprovided for controlling a transition from air motor operation tointernal combustion operation in a hybrid internal combustion engine andair motor system. The hybrid internal combustion engine and air motorsystem comprises (a) a chamber including at least one intake valve, atleast one outlet valve, and a drivable member, (b) an air inlet lineincluding, upstream of the at least one intake valve, an air inlet linevalve, (c) an internal combustion engine mode exhaust line comprising aninternal combustion engine mode exhaust line valve downstream of the atleast one exhaust valve, (d) a compressed air line comprising acompressed air line valve downstream of the at least one exhaust valveand upstream of a reservoir, and (e) an air motor mode exhaust linecomprising an air motor mode exhaust valve downstream of the at leastone intake valve and the air inlet line valve. The method comprisestransitioning from operation in the air motor mode to operation in theinternal combustion engine mode by performing the steps of: a) partiallyopening the internal combustion engine mode exhaust line valve; b)partially closing the air motor exhaust line valve; c) partially closingthe compressed air line valve; d) completely opening the air inlet linevalve after performing steps a), b), and c); and e) changing an intakeand exhaust valve opening and closing timing sequence from an air motortiming sequence to an internal combustion engine timing sequence.

In accordance with another aspect of the present invention, a method isprovided for operating a hybrid internal combustion engine and air motorsystem comprising at least one chamber having a drivable member and atleast one intake valve and at least one exhaust valve, and a reservoirconnected to the chamber through at least one of the intake valve andthe exhaust valve. According to the method, in an air compressor mode ofoperation, air compressor efficiency (ηAC) is calculated, and an intakeand exhaust valve opening and closing timing sequence is selected formaximizing air compressor efficiency so that

$\frac{\left( {\eta \; {AC}} \right)}{\left( {{Valve}\mspace{14mu} {Timing}} \right)} = 0$and$\frac{^{2}\left( {\eta \; {AC}} \right)}{^{2}\left( {{Valve}\mspace{14mu} {Timing}} \right)} < 0.$

In accordance with another aspect of the present invention, a method isprovided for operating a hybrid internal combustion engine and air motorsystem comprising at least one chamber having a drivable member and atleast one intake valve and at least one exhaust valve, and a reservoirconnected to the chamber through the exhaust valve. According to themethod, in an air motor mode of operation, air motor efficiency (ηAM) iscalculated, and an intake and exhaust valve opening and closing timingsequence is selected for maximizing air motor efficiency so that

$\frac{\left( {\eta \; {AM}} \right)}{\left( {{Valve}\mspace{14mu} {Timing}} \right)} = 0$and$\frac{^{2}\left( {\eta \; {AM}} \right)}{^{2}\left( {{Valve}\mspace{14mu} {Timing}} \right)} < 0.$

In accordance with another aspect of the present invention, a hybridinternal combustion engine and air motor system is provided andcomprises at least one chamber having a drivable member and at least oneintake valve and at least one exhaust valve, and a reservoir connectedto the chamber through at least one of the intake valve and the exhaustvalve. The system further comprises a computer configured to calculateair compressor efficiency (ηAC) during an air compressor mode ofoperation and select an intake and exhaust valve opening and closingtiming sequence for maximizing air compressor efficiency so that

$\frac{\left( {\eta \; {AC}} \right)}{\left( {{Valve}\mspace{14mu} {Timing}} \right)} = 0$and$\frac{^{2}\left( {\eta \; {AC}} \right)}{^{2}\left( {{Valve}\mspace{14mu} {Timing}} \right)} < 0.$

In accordance with another aspect of the present invention, a hybridinternal combustion engine and air motor system is provided andcomprises at least one chamber having a drivable member and at least oneintake valve and at least one exhaust valve, and a reservoir connectedto the chamber through at least one of the intake valve and the exhaustvalve. The system further comprises a computer configured to calculateair motor efficiency (ηAM) during an air motor mode of operation andselect an intake and exhaust valve opening and closing timing sequencefor maximizing air motor efficiency so that

$\frac{\left( {\eta \; {AM}} \right)}{\left( {{Valve}\mspace{14mu} {Timing}} \right)} = 0$and$\frac{^{2}\left( {\eta \; {AM}} \right)}{^{2}\left( {{Valve}\mspace{14mu} {Timing}} \right)} < 0.$

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the present invention are well understoodby reading the following detailed description in conjunction with thedrawings in which like numerals indicate similar elements and in which:

FIGS. 1A-1D show a cylinder of a system according to an embodiment ofthe present invention during different phases of a system operatingcycle;

FIG. 2 schematically shows a system according to an embodiment of thepresent invention wherein the system is operated in an air compressormode;

FIG. 3 schematically shows a system according to an embodiment of thepresent invention wherein the system is operated in an air motor mode;

FIG. 4 schematically shows a system according to an embodiment of thepresent invention wherein the system is operated in an internalcombustion engine mode;

FIG. 5 schematically shows a system according to an embodiment of thepresent invention wherein the system is operated in both an internalcombustion engine mode and in an air motor mode;

FIG. 6 schematically shows a system according to an embodiment of thepresent invention wherein the system is operated in both an internalcombustion engine mode and in an air compressor mode;

FIG. 7 is a graph showing intake and exhaust valve opening and closingsequences for a six cylinder engine according to an embodiment of thepresent invention during a transition from an air motor mode ofoperation to an internal combustion engine mode of operation.

DETAILED DESCRIPTION

A hybrid internal combustion engine and air motor system 21 (generallyreferred to as a “system”, “engine”, or “motor” herein) is shown inFIGS. 2-6. The system 21 can be used to drive a variety of machines andis presently considered to have particular applicability in machinessuch as motor vehicles. The system 21 typically includes at least onechamber that may be of the type as shown in FIGS. 1A-1D, such as acylinder 23, having a piston, such as a piston 25, and at least oneintake valve 27 and at least one exhaust valve 29. While the inventionwill be described primarily in connection with a system 21 comprising acylinder in the form of the cylinder 25 and a piston in the form of thepiston 25, it will be appreciated that the invention is adapted to beused with other types of chamber/piston arrangements, such as rotaryengines (not shown). It will also be appreciated that the invention cancomprise a system having a plurality of chambers or cylinders.Typically, the cylinder 23 will comprise a plurality of cylinders, e.g.,23 a-23 f, each with a respective piston and at least one, often two,respective intake valve(s) 27 a-27 f and at least one, often two,respective exhaust valve(s) 29 a-29 f.

The system 21 further comprises a reservoir 31 connected to the cylinder23 through at least one of the intake valve 27 and the exhaust valve 29.The system 21 can also comprise an air inlet line 33 that may include,in parallel, a first branch 35 comprising a charge air cooler valve 37and a second branch 39 comprising a compressor 41 of a turbocharger 43and, downstream of the first and second branches and upstream of the atleast one intake valve 27, a charge air cooler 45 and an air inlet linevalve 47. The charge air cooler valve 37 permits air flow tosubstantially bypass the compressor 41 and the charge air cooler 45 whenthe charge air cooler valve 37 is open and, when it is closed, ensuresthat air passes through the compressor and the charge air cooler.

The system 21 can also comprise an IC mode exhaust line 49 that cancomprise an IC mode exhaust line valve 51 downstream of the at least oneexhaust valve 29 and upstream of a turbine 55 of the turbocharger 43 inthe IC mode exhaust line 49. The system 21 can also comprise acompressed air line 57 that can comprise a compressed air line valve 59downstream of the at least one exhaust valve 29 and upstream of thereservoir 31. The system 21 can also comprise an AM mode exhaust line 61that can comprise an AM mode exhaust valve 63 downstream of the at leastone intake valve 27 and the air inlet line valve 47.

The system 21 can comprise substantially any type of internal combustionengine arrangement, however, it shall be described in connection with adiesel engine arrangement. In the illustrated embodiments, the dieselengine can comprise an exhaust gas recirculation (EGR) line 65 betweenthe IC mode exhaust line 49 and the air inlet line 33, typically joiningthe air inlet line upstream of the air inlet line valve 47. The EGR line61 can comprise an EGR valve 67 and an EGR cooler 69. The IC modeexhaust line 49 can comprise aftertreatment devices such as a dieselparticulate filter 71 and the like.

The system 21 is operable in one or more of what shall be referred to asan air compressor (AC) mode (FIG. 2), an air motor (AM) mode (FIG. 3),and an internal combustion engine (IC) mode (FIG. 4). When operating inan AM mode or an IC mode, the system 21 is primarily used to deliverenergy, such as to power a vehicle. When operating in an AC mode, thesystem 21 is primarily used to absorb kinetic energy, such as duringengine braking, and store it in the form of compressed air. It is alsopossible to simultaneously operate the system 21 in different modes,such as by injecting compressed air into a cylinder on a first downwardstroke (AM mode) of a piston and operating in IC mode during a seconddownward stroke, or by operating a multi-cylinder engine so that somecylinders are run in AM mode and some are run in IC mode, or so thatsome cylinders are run in IC mode and others are run in AC mode.

In the AC mode, an opening and closing timing sequence for the intakevalve 27 and for the exhaust valve 29 can be selected to maximize aircompressor efficiency (ηAC), i.e., so that:

$\frac{\left( {\eta \; {AC}} \right)}{\left( {{Valve}\mspace{14mu} {Timing}} \right)} = 0$and$\frac{^{2}\left( {\eta \; {AC}} \right)}{^{2}\left( {{Valve}\mspace{14mu} {Timing}} \right)} < 0$

Similarly, in the AM mode, an opening and closing timing sequence forthe intake and exhaust valves 27 and 29 can be selected for maximizingair motor efficiency (ηAM), i.e., so that:

$\frac{\left( {\eta \; {AM}} \right)}{\left( {{Valve}\mspace{14mu} {Timing}} \right)} = 0$and$\frac{^{2}\left( {\eta \; {AM}} \right)}{^{2}\left( {{Valve}\mspace{14mu} {Timing}} \right)} < 0$

Air compressor efficiency at different intake and exhaust valve timingsequences can be calculated according to the following equation:

${\eta \; {AC}} = {{{efficiency}\mspace{14mu} {of}\mspace{14mu} {air}\mspace{14mu} {compressor}} = {- \frac{A}{W}}}$

and wherein

$\begin{matrix}{A = {{thermodynamic}\mspace{14mu} {availability}\mspace{14mu} {in}\mspace{14mu} {resevoir}}} \\{= {\left( {E - E_{o}} \right) + {P_{o}*\left( {V - V_{o}} \right)} - {T_{o}*\left( {S - S_{o}} \right)}}}\end{matrix}$

dA=rate of change of A

E=Internal energy of air in reservoir=f(m, T_(t))

m=mass of air in reservoir=P_(t)*V/(R*T_(t))

T_(t)=Temperature of air in reservoir

P_(t)=Pressure of air in reservoir

V=Volume of reservoir at P_(t) and T_(t)

R=gas constant

E_(o)=Internal energy of air in reservoir at ambient pressure andtemperature

P_(o)=Ambient pressure

V_(o)=Volume of air in reservoir at ambient pressure and temperature

T_(o)=Temperature of ambient air

S=Entropy of air in reservoir=f (P_(t), T_(t))

S_(o)=Entropy of air in reservoir at ambient pressure and temperature

POW=Engine brake power=N*T_(b)

N=Engine speed (rev/time)

T_(b)=Engine brake torque

W=Engine brake work=POW dt

dW=rate of change of W

Similarly, in an AM mode of operation, air motor efficiency can becalculated at different intake and exhaust valve timing sequencesaccording to the following equation:

${\eta {AM}} = {{{efficiency}\mspace{14mu} {of}\mspace{14mu} {air}\mspace{14mu} {motor}}\mspace{14mu} = {- \frac{W}{A}}}$

To ascertain maximum air compressor efficiency and air motor efficiencyunder different circumstances, e.g., engine speeds, reservoir pressures,ambient temperatures, etc., can be ascertained, a test system can be setup. For example, in AC mode, as seen in FIG. 2, the intake valve 27 canbe open while the volume of the cylinder 23 is increasing (piston 25downstroke), and while the cylinder gets filtered outside air throughthe air inlet line 33. The IC engine mode exhaust line valve 51 can beclosed and the compressed air line valve 59 can be opened. Air that iscompressed in the cylinder exits the exhaust valve 29 and is deliveredto the reservoir 31 through the compressed air line 57. In the AC mode,braking of the system 21 can occur, and the amount of braking is notcontrolled by restriction which destroys thermodynamic availability andin turn reduces the engine efficiency. Instead, the amount of braking iscontrolled by carefully selecting opening and closing timings of theintake and exhaust valves.

For example, to achieve a targeted amount of braking power at a givenspeed of the system 21 and a given reservoir 31 pressure, a set of valvetimings can be fetched from a stored table or database, which can bepre-determined through a suitable optimization process. In one suitableform of optimization process, the system 21 can be set up in adynamometer test cell (not shown). Fuel injection can be shut off. Thereservoir 31 pressure can be regulated to a constant pressure. Thesystem 21 can be motored by the dynamometer to run in AC mode. A controlsystem (not shown) is set up to sweep through the exhaust valve 29opening (EVO) timing, exhaust valve closing (EVC) timing, and intakevalve 27 opening (IVO) timing while maintaining a constant intake valveclosing (IVC) timing and a constant system speed (N). Meanwhile a datacollection system (not shown) collects the ambient air pressure (P_(o)),ambient air temperature (T_(o)), reservoir pressure (P_(t)), reservoirtemperature (T_(t)), system speed (N) and system brake torque (Tb).Using the collected data within each system cycle, system brake power(W) can be calculated: W=N*Tb.

Also, the internal energy (E) of the air in reservoir can be calculatedonce P_(t) and T_(t) are measured; V is reservoir volume at P_(t) andT_(t), usually a constant so that the volume of the reservoir 31 atambient conditions (V_(o)) is ordinarily equal to V; S is entropy of theair in the tank, which is a function of P_(t) and T_(t); E_(o) and S_(o)are the corresponding properties at the ambient condition. For areservoir 31 of constant volume V, the air mass (m) can be calculatedaccording to the well known equation: m=P*V/(R*T). Energy (E) of gas inthe reservoir 31 is a function of air mass (m) and temperature (T_(t))in the reservoir. The thermodynamic availability (A) in reservoir equals(E−E_(o))+P_(o)*(V−V_(o))−T_(o)*(S−S_(o)).

Efficiency of the system in the AC mode (ηAC) can be determinedaccording to the equation −dA/dW, where dA is the rate of change of thethermodynamic availability of air collected in the reservoir and dW isthe rate of change of system brake work.

Next, the change in efficiency of the system 21 in the AC mode can bedetermined at different valve timings. When d(ηAC)/d(valve timing)=0, aparticular valve timing will be considered to be the optimum valvetiming for the conditions under investigation. For example, if the valvetiming is EVO, EVO will be selected as the optimum timing whend(ηAC)/d(EVO) is small enough, preferably equal to 0. Optimum timing canbe determined by searching through all possible values for EVO.Alternatively, timing can be optimized using an analytical equation ofηAC=f(EVO) which can be constructed using measured values; the optimalEVO can be calculated at df/d(EVO)=: 0.

To illustrate, during a first phase of testing, EVO is set at 330° ofcrank angle (CA), the system 21 is run and yields an efficiency(ηAC₃)=0.7. During a second phase of testing, EVO is set at 331° C.A,the system is run and yields an efficiency ηAC₃₃₁=0.71. Since EVO takesdiscrete values, d(ηAC)id(EVO)=delta(ηAC)delta(EVO)=0.01 in this case.This illustrates a somewhat exhaustive technique of searching throughall possible values for EVO.

To illustrate another approach, the system 21 can be run at three ormore EVO timings, say at EVO=330°, 331°, 332°, and 333° CA. It will beassumed that, at these EVO values, efficiency ηAC=0.7, 0.71, 0.72,0.715, respectively. An equation can be constructed:ηAC=C0+C*EVO+C2*EVÔ2. This equation assumes the shape of the efficiencycurve can be approximated as a second order polynomial, which isbelieved to be a fairly reasonable assumption as long as the optimalvalue lies between the selected points. C0, C1 and C2 can be calculatedby fitting the four pairs of data to the equation. Three sets of valuescan be plugged into the equation above, providing:

ηAC ₁ =C0+C1*EVO ₁ +C2*EVO ₁̂2

ηAC ₂ =C0+C1*EVO ₂ +C2*EVO ₂̂2

ηAC ₃ ==C0+C1*EVO ₃ ++C2*EVO ₃̂2

Next, the following definitions are provided:

B=[ηAC₁, ηAC₂, ηAC₃]

A=[1 EVO₁ EVÔ2

1 EVO₂ EVO₂̂2

1 EVO₃ EVO₃̂]

X=[C0 C1 C2] Then: AX=B Therefore: X=A⁻¹B

Then, the derivative of the second order equation above is:d(ηAC))d(EVO)=C1+2*C2*EVO.When d(ηAC)/d(EVO): 0 then −C1=2*C2*EVO and the optimal EVO=−C1/(2*C2).

Once an optimal value for EVO is calculated at the first IVC, the testis repeated at a next IVC timing, system speed, and reservoir pressurepoint, until all the IVC timings, engine speeds and reservoir pressuresare tested. In an iterative process, where several variables affectefficiency, all of the variables (e.g., IVC, IVO, EVC) except one (e.g.,EVO) can be frozen, and tests can be run by varying that variable. Next,all of the variables (e.g., IVO, EVC, EVO) except another one (e.g.,IVC) can be frozen, and tests can be run by varying that variable, etc.,until tests have been performed for all of the variables. Then furthertests can be run to determine, for example, what optimal values are forone variable when an optimal value for another one of the variables isselected. The optimum timings (IVC, IVO, EVO, EVO) at a given systemspeed and reservoir pressure are then stored in an engine control unit,e.g., computer, and can be used for system control in the AC mode.

As seen in FIG. 3, in AM mode operation, the intake valve 25 is openwhile the cylinder 23 volume is increasing and the cylinder receives airfrom the reservoir 31 through the compressed air line 57 which, in theillustrated embodiments, is connected to the exhaust valve 29 of thecylinder. The AM mode exhaust valve 63 is open while the volume of thecylinder 23 is decreasing, and exhaust air from the cylinder exits, inthis embodiment, through the cylinder intake valve 27 to the AM modeexhaust line 61. Acceleration of the system 21 can be controlled bycarefully set valve timings. For a targeted acceleration power at agiven system speed, a set of valve timings is fetched from a storedtable, which can be pre-determined through an optimization processsimilar to that described in connection with optimization of the AC modeefficiency, except that the objective is to maximize air motor efficient(ηAM), which is defined as ηAM=−dW/dA.

As seen in FIG. 4, during normal operation in IC mode, fresh charge airenters through the air inlet line 33, usually after passing through anair filter 75. Ordinarily, the CAC valve 37 in the first branch 35 ofthe air inlet line is closed and the charge air is directed through thesecond branch 39 through the compressor 41 of the turbocharger 43 andthen on to the CAC 45. The charge air then passes through the air inletline valve 47 and on to the intake valve of the cylinder. As seen inFIG. 4, there is often an intake manifold 77 leading to a plurality ofintake valves 27 a-27 f of a plurality of cylinders 23 a-23 f,respectively.

In the embodiment shown in FIG. 4, the intake manifold 77 also functionsin part as the AM mode exhaust line 61 during AM mode operation.However, during IC mode operation, the AM mode exhaust valve 63 istypically closed, except when the system is configured to operatesimultaneously in IC mode and AM mode, e.g., when certain cylindersoperate in IC mode and others operate in AM mode as shown in FIG. 5.

In IC mode operation as shown in FIG. 4, the IC mode exhaust line valve51 is typically open and the compressed air line valve 59 is typicallyclosed. Internal combustion exhaust travels through the IC mode exhaustline 49, usually passing through the turbine 55 of the turbocharger 43.Some exhaust gas may be diverted through the EGR line 65 and EGR cooler69 to re-enter the air inlet line 33, usually upstream of the intakemanifold 77, by opening the EGR valve 67. Exhaust gas downstream of theturbine 55 is typically directed to exhaust aftertreatment devices suchas the DPF 71.

In an embodiment of the AM mode operation seen in FIG. 3, the air inletline valve 47 is typically closed, as is the IC mode exhaust line valve51. The compressed air line valve 59 and the AM mode exhaust valve 63are typically open. Compressed air from the reservoir 31 flows throughthe compressed air line 57 to the exhaust manifold 79 which, in AM modein this embodiment, functions as an intake manifold. From the exhaustmanifold 79, the compressed air flows to the cylinders 23 a-23 f as theexhaust valves 29 a-29 f in those cylinders—which function as intakevalves in this embodiment—open to force the pistons in those cylindersdown. When an exhaust valve of a cylinder closes, an intake valve—whichfunctions as an exhaust valve in this embodiment—subsequently opens andthe air in the cylinder is exhausted through the intake valve to theintake manifold—which functions as an exhaust manifold in thisembodiment—and through the AM mode exhaust line, which may connect tothe IC mode exhaust line, usually downstream of the turbine 55 and thenflow to the aftertreatment equipment such as the DPF 71.

In an embodiment of the AC mode operation shown in FIG. 2, the CAC valve37 and the air inlet line valve 47 will typically be open, and the ICmode exhaust line valve 51 and the AM mode exhaust valve 63 willtypically be closed. In addition, the compressed air line valve 59 willbe open. The pistons in the cylinders 23 a-23 f will typically bereciprocating during, for example, engine braking, although, as shown inFIG. 6, some cylinders may be operating in an IC engine mode whileothers operate in an AC mode and pistons in the AC mode cylinders aremoved as the result of IC mode operation of the other cylinders movingthe pistons in those cylinders.

Air flows through the air inlet line 33 to the intake manifold 77 and,when the intake valves 27 a-27 f open, air flows into the cylinders 23a-23 f, respectively. During downstrokes of the respective pistons inthe cylinders 23 a-23 f, the valves 23 a-23 f are opened for a periodand the cylinders fill with fresh air. The valves 27 a-27 f are closedand the pistons move upward in the cylinders 23 a-23 f. When the pistonsmove upward in the cylinders 23 a-23 f, the exhaust valves 29 a-29 f areopened, and the air in the cylinders is pushed into the exhaust manifold79, which is connected to the reservoir 31 via the compressed air line57, and the reservoir is thereby pressurized.

FIG. 5 shows an embodiment of the system 21 wherein certain cylinders 23a-23 d operate in IC engine mode and other cylinders 23 e-23 f operatein AM mode. In this embodiment, an intake manifold valve 81 can beclosed to divide the intake manifold into two sections, a first sectionassociated with cylinders 23 a-23 d functioning as an intake manifold inthe conventional manner of the IC engine mode, and a second sectionassociated with cylinders 23 e-23 f functioning as an exhaust manifoldin the manner of the AM mode. An exhaust manifold valve 83 can be closedto divide the exhaust manifold 79 into two sections, the first sectionassociated with the cylinders 23 a-23 d and the second section connectedto the cylinders 23 e-23 f. The cylinders 23 a-23 d are exhaustedthrough the exhaust manifold 79 in the conventional manner for IC modeoperation, i.e., to the IC mode exhaust line 49, while the cylinders 23e-23 f are exhausted through the intake manifold 77 to the AM modeexhaust line 61, which may be connected to the IC mode exhaust line.

FIG. 6 shows an embodiment of the system 21 wherein certain cylinders 23a-23 d operate in IC engine mode and other cylinders 23 e-23 f operatein AC mode. In this embodiment, the intake manifold valve 81 can be openso that air enters the cylinders 23 a-23 f through the intake valves 27a-27 f in the conventional manner for IC mode operation or AC modeoperation. Fuel injection occurs in cylinders 23 a-23 d in theconventional manner for IC mode operation, while no fuel injectionoccurs in cylinders 23 e-23 f. The exhaust manifold valve 83 can beclosed to divide the exhaust manifold 79 into two sections, the firstsection associated with the cylinders 23 a-23 d and the second sectionconnected to the cylinders 23 e-23 f. The cylinders 23 a-23 d areexhausted through the exhaust manifold 79 in the conventional manner forIC mode operation, i.e., to the IC mode exhaust line 49, while thecylinders 23 e-23 f are exhausted through the exhaust manifold 79 to thecompressed air line 57, which is connected to the reservoir 31 topressurize the reservoir.

In the embodiment of the system 21 shown in FIGS. 2-6, during atransition from operation in the AM mode (FIG. 3) to operation in the ICmode (FIG. 4), where the direction of fluid flow through the cylinders23 a-23 f is reversed, it is desirable to minimize torque drop and avoida period during which there is no power. According to an aspect of thepresent invention, this is accomplished by performing a series of stepsincluding partially opening the IC mode exhaust line valve 51 so thatair flow through the turbine 55 will boost air intake through thecompressor 41. This may cause a pressure drop in the exhaust manifold 79so valve timings will ordinarily need to be adjusted accordingly tomaintain brake mean effective pressure (BMEP). Valve timings aretypically adjusted based on pre-calculated maps, ordinarily using avariable valve timing mechanism (not shown).

Ordinarily at about the same time that the IC mode exhaust line valve 51is partially opened, the AM exhaust line valve 63 is partially closed tobuild up pressure at the intake manifold 77. If this takes more than onecycle of the system, valve timings will need to be adjusted accordinglyto maintain BMEP. Also, ordinarily at about the same time, thecompressed air line valve 59 is partially closed. The IC mode exhaustline valve 51 may be partially opened, the AM exhaust line valve 63 maybe partially closed, and the compressed air line valve 59 may bepartially closed all at the same time, or at about the same time.

Ordinarily only after partially opening the IC mode exhaust line,partially closing the AM exhaust line valve 63, and partially closingthe compressed air line valve 59, the air inlet line valve 47 is thencompletely opened and the CAC valve 37 is completely closed. It willordinarily be desirable to have the air inlet line valve 47 open beforethe CAC valve 37 is completely closed to avoid potential turbo surge.The CAC valve 37 is ordinarily kept open initially when the air inletline valve 47 is closed during AM mode to avoid potential turbo surge.However, the CAC valve 37 ordinarily should be fully closed in order forthe turbocharger to boost the pressure of the intake manifold.Therefore, ordinarily, opening of the air inlet line valve 47 commencesand then the CAC valve 37 is completely closed. The pressure of theintake manifold will start to build up after the CAC valve 37 is fullyclosed, with the air inlet valve 47 partially or fully open.

Next, the compressed air line valve 59 can be completely closed.Ordinarily only after the compressed air line valve 59 is completelyclosed, the intake and exhaust valve 27 a-27 f and 29 a-29 f opening andclosing timing sequence can be changed from an air motor timing sequenceto an internal combustion engine timing sequence, as shown in FIG. 7.Ordinarily only after the timing sequence is changed, the AM exhaustline valve 63 can be completely closed, and the IC mode exhaust linevalve 41 can be completely opened.

The compressed air line valve 59 will ordinarily be completely closedwhen the first of any of the following conditions are satisfied: (a) aspeed of the turbocharger 43 reaches a predetermined turbocharger speedlevel, which may occur as a result of partially opening the IC modeexhaust line valve 51 with or without substantially simultaneouslypartially opening the air inlet line valve 47; (b) pressure in the ICmode exhaust line 49 falls to a predetermined IC mode exhaust linepressure; and (c) pressure in the reservoir drops to a predeterminedreservoir pressure level.

During a transition from the IC mode to the AM mode, the system 21 willtypically at least briefly operate in the AC mode as the IC mode exhaustline valve 51 closes and the compressed air line valve 59 opens.Depending upon the timing of the closure of the valves 51 and 59, suchas if the exhaust line valve closes before the compressed air line valveopens and/or before combustion in all of the cylinders is completed,some combustion gases in the exhaust manifold 79 may be directed to thereservoir, although it will ordinarily be desirable to avoid thiscondition as combustion gases can have undesirable effects in thereservoir, such as corrosion.

FIGS. 1A-1D show phases in conventional IC mode operation of a cylinder23. During an intake phase as shown in FIG. 1A, the intake valve 27 isopen and the exhaust valve 29 is closed as the piston 25 moves downwardin the cylinder 23 and charge air enters the cylinder. During acompression phase as shown in FIG. 1B, the intake valve 27 and theexhaust valve 29 are closed as the piston 25 moves upward in thecylinder 23 to compress the air. After fuel injection and combustion, anexpansion phase occurs as shown in FIG. 1C, during which the intakevalve 27 and the exhaust valve 29 remain closed as the piston 25 isforced downward in the cylinder 23 by the combusting fuel. During theexhaust phase as shown in FIG. 1D, the exhaust valve opens 29 while theintake valve 27 remains closed and the upward movement of the piston 25forces the exhaust gas out of the cylinder 23.

In an embodiment arranged like the system shown in FIGS. 2-6, during AMmode operation, in the cylinder shown in FIGS. 1A-1D, compressed airfrom the reservoir 31 can enter the cylinder 23 through the exhaustvalve 29 as shown in phantom in FIG. 1A to force the piston 25 downward.Generally by or before a time when the piston 25 reaches a lowest point,the exhaust valve 29 is closed. As the piston 25 rises in the cylinder,the intake valve 27 is opened to permit air in the cylinder 23 to beexhausted as shown in phantom in FIG. 1D, after which the intake valve27 is closed.

In an embodiment arranged like the system shown in FIGS. 2-6, during ACmode operation, in the cylinder shown in FIGS. 1A-1D, air can enter thecylinder 23 through the intake valve 27 as shown in FIG. 1A as thepiston descends in the cylinder. At or near the point at which thepiston 25 is at its lowest position in the cylinder 23, the intake valve27 is closed and the exhaust valve 29 is opened. As the piston 25 risesin the cylinder 23, the air in the cylinder is forced out the exhaustvalve 29 and may be stored in the reservoir 31.

A compressed air assist mode of operation can comprise drawing air fromthe reservoir 31 through the exhaust valve 29 and into the cylinder 23during a first downward stroke of the piston 25 as shown in FIG. 1A,with or without the intake valve 27 also being open. Injected fuel canbe combusted in the cylinder 23 to urge the piston 25 downward during asecond downward stroke of the piston as shown in FIG. 1C. In this way,the compressed air in the reservoir can function in a manner similar toa compressor of a turbocharger.

In the present application, the use of terms such as “including” isopen-ended and is intended to have the same meaning as terms such as“comprising” and not preclude the presence of other structure, material,or acts. Similarly, though the use of terms such as “can” or “may” isintended to be open-ended and to reflect that structure, material, oracts are not necessary, the failure to use such terms is not intended toreflect that structure, material, or acts are essential.

To the extent that structure, material, or acts are presently consideredto be essential, they are identified as such.

While this invention has been illustrated and described in accordancewith a preferred embodiment, it is recognized that variations andchanges may be made therein without departing from the invention as setforth in the claims.

1-20. (canceled)
 21. A method for controlling a transition from airmotor operation to internal combustion operation in a hybrid internalcombustion engine and air motor system, the hybrid internal combustionengine and air motor system comprising (a) a chamber including at leastone intake valve, at least one outlet valve, and a drivable member, (b)an air inlet line including, upstream of the at least one intake valve,an air inlet line valve, (c) an internal combustion engine mode exhaustline comprising an internal combustion engine mode exhaust line valvedownstream of the at least one exhaust valve, (d) a compressed air linecomprising a compressed air line valve downstream of the at least oneexhaust valve and upstream of a reservoir, and (e) an air motor modeexhaust line comprising an air motor mode exhaust valve downstream ofthe at least one intake valve and the air inlet line valve, the methodcomprising transitioning from operation in the air motor mode tooperation in the internal combustion engine mode by performing, inorder, the steps of: a) partially opening the internal combustion enginemode exhaust line valve; b) partially closing the air motor exhaust linevalve; c) partially closing the compressed air line valve; and d)completely opening the air inlet line valve after performing steps a),b), and c); e) changing an intake and exhaust valve opening and closingtiming sequence from an air motor timing sequence to an internalcombustion engine timing sequence. 22-27. (canceled)